Structural brace for modular housing module

ABSTRACT

A structural brace for a pre-fabricated housing module includes (a) a temporary beam connecting two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module; (b) ceiling bracing panels each providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and (c) wall bracing panels each providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module. A further transverse beam may be provided to connect the ceiling bracing panels for greater structural support and to facilitate lifting of the module during transportation. A tarp may be provided to cover the top and exposed sides of the pre-fabricated housing module to prevent damage to the interior on route to an installation site.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to prefabricated housing modules. Inparticular, the present invention relates to structural support fortransporting a prefabricated housing module from its manufacturing siteto its installation site.

2. Discussion of the Related Art

Prefabricated housing derives its cost advantage by performing many ofthe assembly steps required for a housing unit at the factory, ratherthan at the job site. The building block for multi-unit prefabricatedhousing is typically the individual pre-fabricated modules. A typicalmodule may include one or more bedrooms, a living room, a kitchen and abathroom. Each module, typically including all of its exterior andinterior walls, is manufactured and assembled at a manufacturingfacility and transported to the building site for further assembly (ifrequired) and for installation into the multi-unit structure. At abuilding site, a concrete foundation is typically prepared, to which apre-fabricated module is attached and fastened. Typically, forefficiency reasons, the pre-fabricated module and the foundation areboth provided means for the attachment and fastening ahead of theinstallation time. For a multi-story unit, a second floor module is thenstacked on top of and fastened to the first floor unit. If themulti-unit structure has additional stories, additional modules aresimilarly stacked and fastened to the story immediately underneath. Ifthe multi-unit design includes abutting side by side modules, theabutting modules are placed along side each other and fastened along theabutting exterior walls.

It is not unusual to transport a prefabricated module hundreds of milesto an installation site. Therefore, the prefabricated module must havestructural integrity that can withstand the forces experienced on theroad. Typically, structural integrity is provided by the module'sexterior load-bearing side walls and a structural floor and a structuralceiling. As a result, a multi-unit housing unit built with these moduleshas both a structural floor and a structural ceiling between two floors,and two load-bearing walls between abutting side by side units. Incontrast, in custom-built housing, structural integrity can be providedby a single load-bearing structure between floors or between side byside adjacent units. The redundant walls, ceilings and floors inprefabricated modules add significant cost, and because the redundancyis not needed in the final building structure, the additional materialis wasted.

SUMMARY

According to one embodiment of the present invention, a structural bracefor a pre-fabricated housing module includes (a) a temporary beamconnecting two opposite side walls of the pre-fabricated housing modulealong an open side of the pre-fabricated housing module; (b) ceilingbracing panels each providing horizontal temporary structural supportbetween a third side wall of the pre-fabricated housing module and thetemporary beam; and (c) wall bracing panels each providing temporaryvertical structural support between the temporary beam and a floor ofthe pre-fabricated module. A further transverse beam may be provided toconnect the ceiling bracing panels for greater structural support and tofacilitate lifting of the module during transportation. A tarp may beprovided to cover the top and any exposed side of the pre-fabricatedhousing module to prevent damage to the interior on route to aninstallation site.

According to one embodiment of the present invention, a ceiling bracingpanel includes a base board and a number of dimensional lumber piecessecured to the base board which are placed substantially parallel toeach other and spaced at predetermined intervals. A wall bracing panelmay be similarly provided.

The structural brace of the present invention may include steel blocksthat secure the ceiling panels to the studs of a side wall of thepre-fabricated housing module, so as to allow the side wall to bear theweight of the pre-fabricated housing module when it is moved. Additionalstructural support is achieved using hold downs bolted to structuralelements of the side wall. Sound deadened steel plates may be providedfor reducing sound and vibration during transportation.

n one embodiment, the structural brace of the present invention is atemporary structure that provides structural strength to theprefabricated housing unit, as the prefabricated housing unit is movedbetween manufacturing and installation sites. Possibility of the housingunit suffering damages on route to the building site is thereforegreatly reduced. The structural brace is removed at the time ofinstallation. The removed structural brace can be returned to themanufacturing facilities to be reused. The structural brace of thepresent invention therefore eliminates need for redundant walls, floorsand ceilings, thus reducing the waste, as compared to the prior art.

The present invention is better understood upon consideration of thedetailed description below and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows prefabricated housing module 100 before being provide astructural brace.

FIG. 2 shows prefabricated module 100 of FIG. 1 being provided astructural brace for maintaining structural integrity duringtransportation, in accordance with one embodiment of the presentinvention.

FIG. 3 shows tarp 300 being provided over module 100 to provide acovering for module 100 during transportation between the manufacturingfacilities and the building site.

FIG. 4 is an axonometric view of ceiling panel 201.

FIG. 5 shows a cross section of installed structural brace 200.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to one embodiment of the present invention, a structural braceis developed to provide a prefabricated housing module structuralintegrity during transportation between a manufacturing facility and abuilding site where the module is to be installed.

FIG. 1 shows prefabricated housing module 100 before being provided astructure brace. As shown in FIG. 1, prefabricated module 100 is open atone side wall and is not provided a structural ceiling. Module 100includes permanent prefabricated external side walls 101 a, 101 b and101 c, and a structural floor 108. Window frames 102 have been providedand installed in external side walls 101 a and 101 b. Module 100 alsoincludes multiple rooms with multiple interior dividing walls 103installed at the manufacturing facilities. Module 100 is a “buildingenvelop,” to which other interior amenities, such as cabinets, closets,stairs and plumbing connections, are installed at the building site.These other amenities may be separately manufactured at differentmanufacturing facilities (or supplied by other vendors) and provided asmodular “cells” for installation at the building site.

According to the present invention, as module 100 is a unit which abutsa neighboring unit on one of its sides and with another unit stacked ontop, a structural side wall and a structural ceiling is not included. Atthe building site, module 100 is attached and fastened on its open sideto another unit that has a structural side wall. Similarly, at thebuilding site, another module with a structural floor is attached andfastened to the open top to module 100, so that the structural floor ofthe other unit provides the ceiling for module 100. According to thisdesign, therefore, redundant ceilings and side walls are eliminated toachieve material efficiency.

FIG. 2 shows prefabricated housing module 100 being provided structuralbrace 200 for maintaining structural integrity during transportation, inaccordance with one embodiment of the present invention. As shown inFIG. 2, structure brace 200 includes temporary beam 204, ceiling bracingpanels 201 and wall bracing panels 202. Ceiling bracing panels 201 areheld down by steel blocks and hold downs secured on the studs ofexternal side wall 101 b (see FIG. 5). In addition, ceiling bracingpanels 201 are connected in a transverse direction by standard sizedimensional lumber 203 (shown in FIG. 3). Standard size dimensionallumber 203 may be provided, for example, by a 2×6 piece (i.e., twoinches by six inches). FIG. 3 shows tarp 300 being provided over module100 to provide a covering for module 100 during transportation betweenthe manufacturing facilities and the building site, to be removedimmediately prior to installing module 100 at the building site. Tarp300 protects the interior of prefabricated module 100 against externalelements by covering the open ceiling and side. As shown in FIG. 3,module 100 can be moved by a crane using steel cables which are attachedto the load-bearing structures provided on structural braces 200.

FIG. 4 is an axonometric view of ceiling panel 201. As shown in FIG. 4,ceiling bracing panel 201 includes a base board 401, which can beprovided by a ½-inch thick plywood board. On base board 401 is provided2″×4″ dimensional lumber pieces spaced at 24″ apart (on center). Wallbracing panels 202 can be similarly constructed.

FIG. 5 shows a cross section of installed structural brace 200. As shownin FIG. 5, ceiling bracing panel 201 is secured on one side to externalside wall 101 b, which may be provided by a conventional double studparty wall, and on the other side to wall bracing panel 202. Steelblocks 501 are secured to the double stud party wall 504 by ⅝″ bolts(indicated by reference numerals 503), so that the weight of module 100can be borne in the studs in the wall. In addition, hold-downs 505(e.g., HD5A or HTT16) may be provided for further support by horizontalmembers in the double stud party wall. Ceiling bracing panel 201 andwall bracing panel 202 are attached to temporary beam 204, which may beprovided by 4″×8″ dimensional lumber 505.

As discussed above, wall bracing panel 202 may be provided substantiallythe same structure as ceiling bracing panel 201 (e.g., dimensionallumber (e.g., 2×4's) secured to a base board and spaced apart at regularintervals). A riser (indicated by reference numeral 507) having, forexample, the construction of small sections of a double stud party wall,may be provided from floor 108 of prefabricated module 100 to allow wallbrace panel 202 to attach. Such a riser structure would allow wall bracepanel 100 to be attached to module 100 in substantially the same manneras ceiling panel 201 attaches to side wall 101 b. In one embodiment,sound deadened steel (SDS) plates 506 are provided for attachment tofloor 108 of module 100 to limit sound and vibrations in wall bracingpanel 202.

The detailed description above is provided to illustrate specificembodiments of the present invention and is not intended to be limiting.Numerous variations and modifications within the scope of the presentinvention are possible. The present invention is set forth in thefollowing claims.

1. A structural brace for a pre-fabricated housing module, comprising: a temporary beam connecting two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module. a plurality of ceiling bracing panels, each ceiling bracing panel providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and a plurality of wall bracing panels, each wall bracing panel providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module.
 2. A structural brace as in claim 1, further comprising a transverse beam connecting the plurality of ceiling bracing panels.
 3. A structural brace as in claim 1, further comprises a tarp covering for the top of the pre-fabricated housing module.
 4. A structural brace as in claim 1, wherein each ceiling bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.
 5. A structural brace as in claim 1, wherein each wall bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.
 6. A structural brace as in claim 1, further comprises steel blocks secured to the ceiling panels and the third side wall, so as to allow the third side wall to bear the weight of the pre-fabricated housing module when the pre-fabricated housing module is moved.
 7. A structural brace as in claim 6, wherein the steel blocks are bolted to studs provided in the third side wall.
 8. A structural brace as in claim 7, further comprises hold downs bolted to structural elements of the third side wall.
 9. A structural brace as in claim 1, further comprises sound deadened steel plates for reducing sound and vibration during transportation.
 10. A method for providing a structural brace for a pre-fabricated housing module, comprising: providing a temporary beam to connect two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module. providing a plurality of ceiling bracing panels, each ceiling bracing panel providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and providing a plurality of wall bracing panels, each wall bracing panel providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module.
 11. A method as in claim 10, further comprising providing a transverse beam to connect the plurality of ceiling bracing panels.
 12. A method as in claim 10, further comprises providing a tarp to cover the top of the pre-fabricated housing module.
 13. A method as in claim 10, wherein each ceiling bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.
 14. A method as in claim 10, wherein each wall bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.
 15. A method as in claim 10, further comprises providing steel blocks secured to the ceiling panels and the third side wall, so as to allow the third side wall to bear the weight of the pre-fabricated housing module when the pre-fabricated housing module is moved.
 16. A method as in claim 15, wherein the steel blocks are bolted to studs provided in the third side wall.
 17. A method as in claim 16, further comprises hold downs bolted to structural elements of the third side wall.
 18. A method as in claim 10, further comprises providing sound deadened steel plates to reduce sound and vibration during transportation. 